Metal Additive Manufacturing Concepts

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Questions and Answers

What percentage of the nation's GDP is contributed by manufacturing?

45%

35%

25% (correct)

15%

What does mass customization refer to?

Creating products in large quantities with no variation.

Customizing products according to individual customer needs but in low volumes. (correct)

Producing a variety of customized products on a large scale.

Manufacturing products at a fixed price regardless of customization.

Who is eligible to attend the additive manufacturing course?

Individuals interested in new product development, regardless of background. (correct)

Only postgraduate engineering students.

Only people with technical degrees.

Only those with a background in manufacturing.

What is a significant emerging method in manufacturing discussed in the course?

Additive Manufacturing. Signup and view all the answers

In what year was the value of manufacturing in India reported as $403 billion?

2019 Signup and view all the answers

Which of the following statements is true about the course content?

It includes topics of both additive and subtractive manufacturing technologies. Signup and view all the answers

What characterized the industrial age introduced in the 18th century?

The use of mass production to create large quantities of products. Signup and view all the answers

Why is metal additive manufacturing considered an emerging phenomenon?

It is recognized for its efficiency in modern manufacturing. Signup and view all the answers

What must be developed to ensure that AM-made parts used in critical applications are not affected by malicious attacks?

Special validation procedures Signup and view all the answers

What is one significant challenge organizations face regarding the adoption of metal additive manufacturing (AM)?

Lack of AM knowledge and competence Signup and view all the answers

Which phenomenon leads to defects such as porosity in metal additive manufacturing?

Gas absorption Signup and view all the answers

Which of the following is NOT an advantage for companies mastering metal additive manufacturing?

Simplified production processes Signup and view all the answers

What structural factor hinders successful metal additive manufacturing business cases?

Knowledge gap among engineers Signup and view all the answers

What classification is important for understanding the capabilities of additive manufacturing?

Process classification Signup and view all the answers

Which guidelines are applied to control hazards caused by combustible materials in the context of additive manufacturing?

ATEX directives Signup and view all the answers

What must education and training adapt to foster more effective applications of metal additive manufacturing?

Understanding of AM capabilities and limitations Signup and view all the answers

What remains a significant challenge for mass manufacturing in additive manufacturing (AM)?

Reliability and reproducibility issues Signup and view all the answers

Which approach improves control within Direct Energy Deposition (DED) processes?

Implementing closed-loop control Signup and view all the answers

What is a contributing factor to the slow adoption of additive manufacturing in industry?

Shortcomings in existing standards Signup and view all the answers

Which organizations are actively developing standards for additive manufacturing?

ASTM, ANSI, and ISO Signup and view all the answers

What recent advancement is being made in powder bed fusion (PBF) processes?

Incorporating intermittent controllers Signup and view all the answers

What role does Design for AM (DfAM) play in workflow integration?

It aids in automation through digital solutions Signup and view all the answers

Which factor can affect the quality assurance in additive manufacturing?

Variability in temperature and humidity Signup and view all the answers

What is a potential consequence of retracting and amending standards repeatedly in the AM industry?

Diminished industry confidence Signup and view all the answers

What is another common source of heat for thermal-based metal powder bed additive manufacturing technologies?

Electron beam Signup and view all the answers

Which statement best describes flowability?

The capacity of fluids and loose particulate solids to move by flow Signup and view all the answers

Which law quantifies heat transfer processes through a material?

Fourier’s Law Signup and view all the answers

What are functionally graded lattices designed to vary?

Density distribution by varying porosity Signup and view all the answers

What structures are built using repeatable unit cells in a 3D framework according to the content?

Graded lattices Signup and view all the answers

Which of the following is NOT a type of triply periodic minimal surface mentioned in the content?

Prismatic Signup and view all the answers

What is defined as the separation between two consecutive laser beams in additive manufacturing?

Hatch spacing Signup and view all the answers

The capacity of materials to allow heat transfer is influenced by which of the following factors according to Fourier's Law?

The gradient in temperature Signup and view all the answers

What does the heating depth ratio (HDR) primarily relate to?

Spot diameter and scan velocity Signup and view all the answers

Which process is primarily served by image segmentation?

Reducing image complexity Signup and view all the answers

What factor exacerbates intergranular cracking in materials?

Intensification of thermal power Signup and view all the answers

What are intrinsic parameters primarily related to?

Substrate and powder properties Signup and view all the answers

What type of pores are formed due to high energy densities in melt pools?

Keyhole pores Signup and view all the answers

Which characteristic is NOT associated with image segmentation?

Reducing the color depth of images Signup and view all the answers

Which of the following is a consequence of the higher tensile stresses during solidification?

Intergranular cracking Signup and view all the answers

Which of the following parameters is NOT intrinsic to the substrate?

Environmental humidity Signup and view all the answers

Study Notes

Absorption

In Metal Additive Manufacturing, absorption refers to one material (absorbate) being retained by another material (absorbent).
This process can lead to defects like porosity and keyholes due to gas absorption during the molten phase of the metal.

AM Guidelines and Standards

The control of hazards posed by combustible materials has been a focus in recent decades.
Organizations like ATEX and ISO (specifically ISO 60079) have implemented regulations regarding flammable materials.

Electron Beam

In addition to laser beams, electron beams (EB or EBM) are also employed as a common heat source in thermal-based metal powder bed additive manufacturing technologies.

Flowability

Flowability is a characteristic that describes the ability of fluids and loose particulate solids to move through flow.

Fourier’s Law

It quantifies heat transfer processes by stating that the time rate of heat transfer through a material is proportional to the negative gradient in temperature and to the area at right angles to that gradient, through which the heat flows.
This relationship is often expressed in differential form.

Functionally Graded Lattices

These are structures designed with varying porosity distributions by adjusting the volume fractions of each unit cell within the 3D design domain.

Graded Lattice

Utilizes repeatable unit cells in a 3D framework, utilizing implicit surfaces derived from triply periodic minimal surfaces (TPMS). Examples of these include Diamond, Gyroid, and Primitive.

Hatch Spacing/Hatching Distance/ Scan Spacing

It represents the separation between two consecutive laser beams.

Heating Depth Ratio (HDR)

This dimensionless process parameter is calculated as the ratio of heat depth to layer thickness.
The formula for HDR is: HDR = (4𝛼/𝑣)* (𝑑/𝑙) where 𝛼 is the heat transfer coefficient, 𝑙 is the length of the material, 𝑑 is the spot diameter, and 𝑣 is the scan velocity.

Image Segmentation

This method involves breaking down a digital image into subgroups (image segments) to simplify further processing or analysis.
The process involves assigning labels to pixels, where pixels belonging to the same category share a common label.

Intergranular Cracking

Cracking occurs at grain boundaries during the solidification process.
It arises due to higher tensile stresses in the solidifying and cooling material compared to the strength of the solidified metal.
This type of cracking is exacerbated by increased thermal power or substrate thickness.

Intrinsic

Intrinsic parameters are related to the substrate and powder properties such as absorptivity, thermal conductivity, heat capacity, thermal diffusivity, and substrate geometry.

Keyhole

Keyhole pores are formed when vapor bubbles become trapped within the melt pool. This typically occurs at higher energy densities.
Lack of fusion pores is attributed to unmelted regions due to lower energy density.

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Description

Explore key concepts in Metal Additive Manufacturing, including absorption, flowability, and the use of electron beams. Understand the significance of guidelines and standards related to hazardous materials and heat transfer processes through Fourier’s Law. This quiz will test your knowledge on these essential topics.